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PROCESS PARAMETERS
MATERIAL BEHAVIOR
(SYNERGISM)
DESIGNER
PLANT MANGER
FAILURE
(INADEQUATE
PERFORMANCE)
LEAKAGE
FRACTURE
BREAKDOWN
UNACCEPTABLE
DIMENSIONAL
CHANGE
IMPORTANCE OF FAILURE INVESTIGATION
Failure analysis reveals one or more the following:
Deficiencies in design
Material imperfection
Fabrication defects
Improper processing
Errors in assembly
Service abnormalities
Inadequate or improper maintenance
Unintended or inadvertent factors
Stages involved in Failure Investigation:
1. Collection of background data
2. Preliminary examination of the failed part
3. Non-destructive testing / Examination
4. Mechanical Testing
5. Macroscopic Observation
6. Microscopic studies
7. Determination of Failure Mechanism
8. Chemical analysis of the failed portion
9. Analysis of Fracture Mechanics
10. Testing under simulated conditions
11. Analysis and Synthesis of all the evidences, formulation of
conclusions
12. Writing of report
NEW TECHNIQUES FOR FAILURE ANALYSIS
ADVANCED NDE
MINIATURE SPECIMEN TESTING
X-RAY DIFFRACTION
- RESIDUAL STRESSES
MAGNETIC BARKHAUSEN NOISE
- MICROSTRUCTURE
IN-SITU METALLOGRAPHY
TRACE ELEMENTAL ANALYSIS
TYPES OF FAILURES
Crack origin
Basquins Law
(/E) Nf = C = Constant
= Constant (between 1/8 to 1/15);
Nf = Number of cycles to failure
Crack propagates:
In planes perpendicular to the applied stress axis
Characterized by striations (beach marks) on the fracture surface
Photograph of the failed aircraft wheel axle and its fracture surface
STRIATIONS INDICATING SLOW FATIGUE CRACK
GROWTH BEACH MARKS
Failure of a steam turbine blade from a nuclear power plant due to fatigue
To avoid fatigue failures:
MECHANISM OF CREEP
Strain-range-partitoning method
Takes care of creep-fatigue interaction
Strain hold fatigue tests
Stress-strain hysteresis loop partitioned to obtain contribution of
creep and fatigue in each cycle
Ductility-exhaustion method
Fraction of ductility consumed in each strain hold test is calculated
Applied to power plant components
ENVIRONMENTAL FAILURE
Corrosion failure
Storage condition
TYPES OF CORROSION
Uniform corrosion
Pitting corrosion
Selective leaching
Intergranular corrosion
Concentration cell
corrosion
Crevice corrosion
Galvanic corrosion
CORROSION RATE EXPRESSION
Modification of metals
Modification of environments
Change of metal/environmental potential
Use of nonmetallic materials
Trepanned portion
Cu depleted zone
Delamination
Branched TGSCC initiation from corrosion pits due to chloride ion attack from the
mineral insulation wool from the outer surface of the stainless steel tube
Pitting corrosion observed on cut cross section of a
cupro-nickel tube from a turbine lub-oil cooler
MECHANICAL ENVIRONMENTAL FAILURES
STRESS CORROSION CRACKING
HYDROGEN EMBRITTLEMENT
General Characteristics:
Only specific environment cause failure
- Season Cracking
Microstructure of the alloy influences susceptibility
Sensitization
Pure metals are less susceptible
Transgranular mode Intergranular mode
Processing - Melting
Fabrication - Welding/Electropolishing
Service in a hydrogen environment - Sour gas / refineries
General characteristics of Hydrogen embrittlement:
MPa
a = EGc
Gc = Energy absorbed by unit area of the crack; Toughness (J/m2)
= Stress ; a = critical size of the crack
a = K = Stress intensity factor (MNm-3/2)
ROBOTICS
REACTOR VESSEL INSPECTION
STEAM GENERATOR INSPECTION (ISI)
E
* ANALYTICAL
N
G
I * REALISTIC
N
E
E
R
I
N
G
G
U
R * INTEGRITY
U
* FIELD SENSE